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Combined Loose Piece Pattern for a Complex Job

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Combined Loose Piece Pattern for a Complex Job View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by ethesis@nitr COMBINED LOOSE PIECE PATTERN FOR A COMPLEX JOB A thesis submitted in partial fulfillment of the requirements for the degree of Bachelor of technology (B.Tech) In Mechanical engineering By SUBRAT MISHRA Roll No-110ME0309 Department of Mechanical Engineering National Institute of Technology Rourkela COMBINED LOOSE PIECE PATTERN FOR A COMPLEX JOB Submitted In partial fulfillment For the award of the Degree of Bachelor of Technology In Department of Mechanical Engineering, National Institute of Technology, Rourkela, Submitted By :- SUBRAT MISHRA ROLL NO 110ME0309 Under the guidance of :- Dr. SUSANTA KUMAR SAHOO Professor (Department of Mechanical Engineering, NIT Rourkela) Department of Mechanical Engineering NATIONAL INSTITUTE OF TECHNOLOGY ROURKELA 1 C E R T I F I C A B.TechT E Thesis This is to certify that the work in this thesis entitled “Combined loose piece pattern for a complex job” by Subrat Mishra, has been carried out under my supervision in partial fulfillment of the requirements for the degree of Bachelor of Technology in Mechanical Engineering during session 2013-2014 in the Department of Mechanical Engineering, National Institute of Technology, Rourkela. To the best of my knowledge, this work has not been submitted to any other University/Institute for the award of any degree or diploma. Date: 07/05/2014 Prof. Dr. Susanta Kumar Sahoo professor Department of Mechanical Engineering National Institute of Tchnology Rourkela ACKNOWLEDGEMENTB.Tech Thesis I take this opportunity as a privilege to thank all individuals without whose support and guidance I could not have completed our project in this stipulated period of time. First and foremost I would like to express my gratitude to Project Supervisor Prof. S K Sahoo, Department of Mechanical Engineering, National Institute of Technology, Rourkela for his precious guidance, support and encouragement during the tenure of this work. His insights, comments and undaunted cooperation in every aspect of the project work have led to the successful completion of the project. I am also thankful to Dr. K. P. Maity, H.O.D of Department of Mechanical Engineering, National Institute of Technology, Rourkela for his constant support and encouragement. Last, but not the least I extend my sincere thanks to all faculty members of Mechanical Engineering Department for making my project a successful one, for their valuable advice in every stage and also giving me absolute working environment where I unlashed my potential. I would like to thank all whose direct and indirect support helped me completing my thesis in time. I want to convey my heartiest gratitude to my parents for their unfathomable encouragement. SUBRAT MISHRA Roll No 110ME0309 Department of Mechanical Engineering National Institute of Technology Rourkela CONTENTS B.Tech Thesis CERTIFICATE……………………………………………………………………………………………………………..(I) ACKNOWLEDGEMENT……………………………………………………………………………………………….(II) ABSTRACT…………………………………………………………………………………………………………………(III) LIST OF FIGURES AND TABLES…………………………………………………………………………………….(IV) Chapter 1 INTRODUCTION……………………………………………………………………………………… 1-11 1.1 Different types of Casting and its processes 1.2 Sand casting in details 1.3 Patterns used in sand casting and its types 1.4 Description about various types of pattern 1.5 Pattern allowances Chapter 2 OBJECTIVES AND THE PRESENT WORK…………………………………………………………12 Chapter 3 LITERATURE REVIEW…………………………………………………………………………………….13-16 Chapter 4 METHODOLOGY ADOPTED DURING PROJECT WORK………………………………………17 Chapter 5 DESIGN AND FABRICATION………………………………………………………………………………18-25 5.1 Valve manufacturing-a brief idea 5.2 Diagram of the valve 5.3 Design and Dimensioning of the pattern 5.4 Dimension of wood pattern 5.5 Fabrication of the wood pattern 5.6 Designing and Drawing Chapter 6 Experimentation and Observation………………………………………………………………………..26 Chapter 7 Conclusion……………………………………………………………………………………………………………..27 Chapter 8 References…………………………………………………………………………………………………………….28 ABSTRACT B.Tech. Thesis Casting is one of the earliest metal-shaping methods known to human being. It generally means pouring molten metal into a refractory mould with a cavity of the shape to be made, and allowing it to solidify. When solidified , the desired metal object is taken out from the refractory mould either by breaking the mould or by taking mould apart. This process is also called founding. A pattern is a replica of the object to be made by the casting process, with some modifications. The main modifications are addition of pattern allowances like shrinkage allowance, machining allowance, draft allowance etc. , the provision of core prints and elimination of fine details. Loose piece pattern is used when the contour of the part is such that withdrawing the pattern from the mould is not possible. Hence during moulding, the obstructing part of the contour is held as a loos piece by a wire. After moulding is over, first the main pattern is removed and then the loose pieces are recovered through the gap generated by the main pattern. A safety valve which is generally manufactured by complex forging method , can be easily manufactured by sand casting method which is more economical the forging method. In the sand casting method, the two wedge shaped portions of the safety valve create problem during removal of pattern, so these two portions are taken as loose pieces and held as loose pieces by a wire or pin. Once the main pattern body is removed, these loose pieces are recovered through the space vacated by main pattern body. So this project work deals with manufacturing of safety valve using sand casting with split pattern which consists of multi loose pieces (combined loose piece). LIST OF TABLES AND FIGURESB.Tech Thesis SL NO DESCRIPTION PAGE NO. Fig 1.1.1 Lost wax casting 1 Fig 1.1.2 Die casting 2 Fig 1.13 Sand casting 2 Fig 1.2.1 Sand casting processes 5 Fig 1.4.1 Single piece pattern 7 Fig 1.4.2 Split pattern 7 Fig 1.4.3 Loose piece pattern 8 Fig 1.5.1 Shrinkage allowance 10 Fig 1.5.2 Machining allowance 10 Fig 1.5.3 Draft allowance 11 Fig 1.5.4 Shake allowance 11 Fig 1.5.5 Distortion allowance 11 Fig 5.2.1 Safety valve 18 Fig 5.4.1 Safety valve with all parts 21 Fig 5.5.1 Cutter saw 24 Fig 5.5.2 Circular saw 24 Fig 5.5.3 chisel 24 Fig 5.5.4 Hand saw 24 Fig 5.5.5 Iron planar 24 Fig 5.6.1 Catia drawing of the safety valve 25 Fig 6.1.1 Handmade wood pattern of the valve 26 Table 5.3.1 Shrinkage allowance table 19 Table 5.3.2 Draft allowance table 20 Table 5.3.3 Machining allowance table 20 Table 5.4.1 Dimension of part 1 22 Table 5.4.2 Dimension of part 2 22 Table 5.4.3 Dimension of part 3 22 Table 5.4.4 Dimension of part 4 23 Table 5.4.5 Dimension of part 5 23 1. INTRODUCTION B.Tech Thesis In metallurgy, casting is to pour molten metal into a mold , which contains a hollow cavity of the desired shape , and then allowing it to cool and solidify. The solidified part is also known as a casting , which is ejected or broken out of the mold to complete the process . Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Casting processes have been known for thousands of years , and widely used for sculpture , especially in bronze, precious metal jewelry , and weapons and tools. Traditional techniques include lost wax casting , plaster mold casting and sand casting . The modern foundry process is divided into two main categories: expendable cast and expendable . Is divided by the mold material , such as sand or metal , and the method of deposition , such as gravity, low pressure or vacuum . 1.1 .Different type of Castings and its process Today Castings is used to create the desired and solid shape. Foundry industries to help them grow. There are different types of castings and lost wax process and die casting, sand casting. Castings are the type of manufacturing process. Lost wax Castings This is the oldest metal forming or casting process. Lost Wax Casting is used for the manufacture of large parts such as the wheels of the turbocharger, golf clubs, choosing a variety of pieces ranging from turbocharger wheels golf clubs, electronic implants replacement boxes hip. Lost wax casting racks used for investment. Today investment racks are used for aircraft engine and airframe parts. Castings lost wax is similar to Lost Foam Casting patterns that are uses disposable foam casting productions. Foam pattern remains in the mold during casting of metal and is replaced by molten metal. Fig 1.1.1(lost wax casting) DEPARTMENT OF MECHANICAL ENGINEERING,NIT ROURKELA Page 1 B.Tech Thesis Die Casting Die casting is one of the casting processes not expandable. Its a type of process in which the molten metal is forced under high pressure into the mold cavities. In the casting mold die is used again and again to produce a variety of casting size, shape and thickness. The pieces, which are manufacture by casting are the heat resistance and maintain tight tolerances. Casting produces parts with thinner walls, closer dimensional limits and smoother surfaces. Fig 1.1.2(die casting) SandCasting Sand casting is used to make large parts. The sand used for sand casting mold. In the sand of the mold cavity is formed from wood or metal pattern. Using the sand casting method, you can convert large iron bell, and alos small auto parts. In sand casting, two types of green sand used as the sand, which is a mixture of silica and olivine foundry sand.Sand used for high volume production. Fig 1.1.3(sand casting) DEPARTMENT OF MECHANICAL ENGINEERING,NIT ROURKELA Page 2 1.2.
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